Feduik Series-Counterflow Green Done Easy · • Typical entering condenser water from tower • Typical entering wet bulb to tower • Typical difference between water leaving the

Copyright © Carrier Corp. 2009 1

Copyright © Carrier Corp. 2009Copyright © Carrier Corp. 2009

Green Done Easyfor

LEED® Certification

Presented By:

© 2009 Carrier Corp.

WelcomeWelcome

Bob Feduik, P.E. LEED APSoftware SystemsCarrier Corporation Syracuse, New York


Today’s FocusToday’s Focus

• Discuss Chillers & Efficiency(Especially New Technology Chillers)

• Define Series Counter-Flow + DOAS + Chilled Beams

• Compare ASHRAE 90.1-2004 “Baseline” Building vs. “Proposed” Building with Series Counter-Flow Chillers


Chiller TypesChiller Types

Section 4 – Direct and Reverse Return Systems


© 2009 Carrier Corp. Section 4 – Direct and Reverse Return Systems

© 2009 Carrier Corp. Section 4 – Direct and Reverse Return Systems

© 2009 Carrier Corp. Section 3 – Chiller Components

© 2009 Carrier Corp. Section 1 – Introduction


© 2009 Carrier Corp. © 2009 Carrier Corp.

Customer TypesCustomer Types


Universities andCentralPlants require

LongevityHigh EfficiencyQuality


Hospitals

Excellent control of humidity and temperature



UpscaleRetail & Lodging

Comfortable quiet environment


Hi rise office Buildings

Architectural fit

Zone capabilities


Special UseFacilities

Utmost In Flexibility

Reliability


Process and Manufacturing

Precise Control

Durability & Efficiency



CentrifugalCentrifugal

ScrollScroll

ReciprocatingReciprocating

ScrewScrew

Chiller Compressor TypesChiller Compressor TypesPositive Displacement

Dynamic


Scroll CompressorScroll Compressor

Hermetic Shell

Suction Inlet

Hermetic Motor

Hot Gas Discharge

Electrical Terminal Connection

Orbiting Scrolls

Pressure Relief

Section 3 – Air-Cooled Chiller Components


Scroll CompressorScroll Compressor

CLICK PICTURE TO RUN DEMO

Section 3 – Air-Cooled Chiller Components© 2009 Carrier Corp.

Semi-Hermetic Reciprocating CompressorSemi-Hermetic Reciprocating Compressor

Electrical Terminal Box

Semi-Hermetic Motor

View Port

6-Cylinder Model Shown

Cylinder Head

Bolted Compressor

Housing




Reciprocating CompressorReciprocating Compressor


Section 3 – Air-Cooled Chiller Components© 2009 Carrier Corp.

Double Rotor Screw CompressorDouble Rotor Screw Compressor

Twin Rotor Design

Semi-Hermetic Housing

Oil Pressure

Capacity Control Mechanism

Motor Terminal Box



Twin Screw CompressionTwin Screw CompressionTypical screw compressors have two rotors.

As gas is compressed, it exerts an equal and opposite force on the rotors.

These large forces try to push the rotors apart.


Double Rotor Screw CompressorDouble Rotor Screw Compressor





Centrifugal – Water-CooledCentrifugal – Water-Cooled

Inlet Guide Vanes

Transmission

Impeller

Guide Vane Motor

Refrigerant Motor Cooling Line

Motor Rotor

Section 3 – Chiller Components© 2009 Carrier Corp.

Centrifugal CompressorCentrifugal Compressor Need Avifile


Section 3 – Chiller Components


Water-Cooled Chiller Advantages• Higher efficiency• Custom selections on larger sizes• Large tonnage capabilities• Indoor chiller location• Longer life

Air-Cooled Chiller Advantages• Lower installed cost• Quicker availability• No cooling tower or condenser

pumps required• Less maintenance• No mechanical room required

Water-Cooled vs. Air-Cooled ChillersWater-Cooled vs. Air-Cooled Chillers

Section 1 – Introduction© 2009 Carrier Corp.

Design Air Inlet Temperature 95° F

Refrigerant Condensing Temperature 125° F

125° F Condensing Temperature

Air-Cooled Condensing TemperatureAir-Cooled Condensing Temperature

Section 1 – Introduction



94.4° F• Typical water leaving the condenser

9.4° F• Water rise in the condenser

85.0 F°78F

• Typical entering condenser water from tower• Typical entering wet bulb to tower

2.6° F• Typical difference between water leaving thecondenser and condensing temperature

97.0° F• Typical water-cooled condensing temperature

=

Water Cooled Condensing TemperaturesWater Cooled Condensing Temperatures

Section 3 – Types of Condensers: Water-Cooled© 2009 Carrier Corp.

Condensing Temperature TopicCondensing Temperature Topic

Section 1 – Introduction


Effect of Condensing TemperatureEffect of Condensing Temperature

Section 3 – Types of Condensers: Evaporative

1591.1553.691.048.10130

133.9647.994.049.84120

115.8342.797.051.41110

107.7740.498.652.15105

100.7238.210052.86100

%TONS%

kW/TONkW/TONkW INPUTCAPACITYCONDENSING

TEMP (°F)

WATER-COOLEDAIR-COOLED

Based on Screw Compressor, 40° F Suction R-134a


89.689.188.688.187.687.186.686.185.685.1

85.084.083.082.081.080.079.078.077.076.0

85.081.077.073.069.065.065.065.065.065.0

100%90%80%70%60%50%40%30%20%10%

ECWTASIA

0.5° F/10%

ECWT Humid Areas of

North America1.0° F/10%

ECWTARI(° F)

Chiller Capacity



First Objective:First Objective:

To understand the theory of chiller lift as it relates to series counter-flow chiller plant design.


64° F 54° F 44° F

Series – (Typically greater than 18° F drop)

54° F

44° F

44° F

44° F

Parallel – (Typically 18° F drop or less)

Section 3 – Chiller Components

Parallel Versus Series EvaporatorsParallel Versus Series Evaporators


Primary-Secondary SystemPrimary-Secondary System

• Secondary pumping station– One pump active, the other standby (lead-lag)– Pumps are VFD-equipped if all coils are 2-way– Matches secondary flow to coil loads

• Hydraulic decoupler maintains constant primary flow

Hydraulic Decoupler

(Bridge)

Production Loop (primary) Building System Loop (secondary)

Section 7 – System Piping Arrangements

Alternate Bypass Line minimum chiller flow


Primary-Only Variable-FlowPrimary-Only Variable-Flow

Flow Meter

Control Valve, sized for minimum chiller flow

Automatic Isolation Valves

Variable Speed Primary Pumps

Bypass

Section 7 – System Piping Arrangements



Next FocusNext Focus





Series Counter-FlowSeries Counter-FlowWhat is it?

Upstream chiller (CH-2) cools 60°F – 52°F

Downstream chiller (CH-1) cools 52°F – 44°F

Evaporator water flows thru CH-2 and then CH-1

Condenser water flows thru CH-1 and then CH-2

90°F

Leaving Chilled Water 44°F

85°F

52°F

95°F

CH-1

CH-2

Entering Chilled Water 60°F


SAT. LIQUID

SAT. VAPOR

Refrigerant Effect(Capacity)

Compr

essio

n

Heat Rejection

Enthalpy

SCT

Reduced Lift

Pres

sure

42

92

97

SST

Lift = Work = Energy

How Does It Work?

System SST SCT Lift

Parallel 42 97 55

Series C-F 42 92 50

Downstream Chiller

90F

60F

44F

85F

52F

95F

Lower Lift = Less Work = Lower kWLift f (SCT-SST) = 92°-42° = 50°F


SAT. LIQUID

SAT. VAPOR

Refrigerant Effect(Capacity)

Compr

essio

n

Heat Rejection

Enthalpy

SCT

Reduced Lift

Pres

sure

42

50

97

SST

90F

60F

44F

85F

52F

95F

How Does It Work?

Upstream Chiller

System SST SCT Lift

Parallel 42 97 55

Series C-F 50 97 47

Lower Lift = Less Work = Lower kW



Positive Displacement Screw Compressor can not Surge

Quickly Adapts To System Changes

134a Positive PressureNo Purge

Semi-Hermetic Motors No Shaft Seal or Alignment.

Heavy Duty ASME Heat Exchangers

Apply New Technology Screws In Series-Counterflow


Shorter Rotors for Stability

Tri-Rotor CompressorTri-Rotor Compressor


Two compression processes occur simultaneously.

Forces from upper compression are equal and opposite to forces from lower compression.

Vastly reduced bearing loads.

Tri-rotor screw compression forces cancel yielding extremely low loads on the bearings.

Tri-Rotor Screw CompressorTri-Rotor Screw Compressor


Reduced load on bearings allows for larger discharge areas – increased efficiency

Tri-rotor has 1/3 the transfer torque of twin rotors. Requires less oil to lubricate rotors.

Reducing losses important at all loads, enormous influence at part loads.

Tri-rotor screw compressor full and part load

efficiencies are superior to traditional screw designs.

Tri-Rotor Screw CompressionTri-Rotor Screw Compression



Evaporator Flow rate cut by half in less than one minute.

Chiller quickly shed the load and stabilized at the new condition.

44F

58F1000 gpm

500 gpm

Quick Response TimeQuick Response Time


Maximize your uptime.

Industrial DesignIndustrial Design

• Positive displacement screw compressor cannot surge

• Quickly adapts to system changes

• 134a positive pressure no purge

• Semi-hermetic motors no shaft seal or alignment

• Heavy duty ASME heat exchangers


Optional Isolation Valves Allow:

Chillers Delivered Fully ChargedReduced Service Time Reduced Service ExpenseReduced Refrigerant Transfer LossesNo Need For External Refrigerant Storage Tanks.Optional Unit Mounted Transfer Compressor (Pump Out).

In Chiller StorageIn Chiller Storage


Entire system is factory testedDrive does not require any additional floor space65,000 amp interrupt capacity circuit breaker standard. (100 KAIC Optional).Single Point Power Easy installation

• Just connect incoming power lines

Factory-Mounted VFDFactory-Mounted VFD



Electrical BenefitsElectrical Benefits

• High Efficiency • High Power Factor • Low KVA, Wire Size • Low inrush amps• Low Harmonic Distortion

(meets IEEE-519 std)• Demand Limit Benefit


0.576 / 0.86

0.576 / 0.99

Full Load Eff / PF

425

374

MCA

Constant Speed 400 Ton Chiller

VFD Screw 400 Ton Chiller

Chiller

Reduced Wire SizeReduced Wire Size

• Higher power factor results in lower Minimum Circuit Ampacity (MCA)

• Can reduce wire size.

• Can reduce breaker size.


600-800%Across the Line

200-275%Wye-Delta

400-500%Part Winding

400-500%Auto Transformer

300%Solid State

100%VFD

Starting Current (% of FLA)

Starter Type

.

• Easily fits into existing electrical systems

• Ideal for generator start up

• Low voltage drop on customer electrical system on start up

• Longer motor life

Lowe InrushLowe Inrush


All variable frequency drives (VFD’s) are not the same.Eliminates complicated harmonics analysisEliminates field installedauxiliary line reactors and filters that consume energy and floor space.

Low THD (Total Harmonic Distortion)

- 519

0%

5%

10%

15%

20%

25%

30%

35%

THD

23XRV VFD

Traditional VFD,with out linereactor

* THD is computed on an electrical system basis, not on individual equipment. The graph is only intended to show relative values.

Low Harmonic DistortionLow Harmonic Distortion



High Energy Bills? 40% more efficient than ASHRAE 90.1

uses chlorine free, non-phase out 134a.

provides maximum tons per amp of existing electrical service and has small footprint.

Condenser Override allows operation at up to 105 F entering condenser water.

starts and operates continuously with cold condenser water (55F).

no purges, shaft seals, slide valves, oil separators or storage tanks required.

low inrush, high power factor and meets IEEE-519 standards for harmonics.

produces up to 15% more tons than some other chillers during periods of reduced ECWT

Refrigerant Phase Out?

Power Quality?

Demand Management?

High Maintenance Costs?

Can’t Lower Tower Set Point?

Tower Problems, Dirty Tubes?

Need More Capacity?

VFD Screw Chiller Solution GuideVFD Screw Chiller Solution Guide


Today’s FocusToday’s Focus





Commercial Office Building with Data CenterCommercial Office Building with Data Center


Chiller Plant Efficiency: Series Counter-FlowChiller Plant Efficiency: Series Counter-FlowOptimized Energy Performance

• ASHRAE 90.1-2004, Appendix G

Whole Building Energy Simulation• Annual Energy Cost ($) and Consumption (kWh)• ASHRAE Recognized Simulation Program, Carrier HAP

Compare “Baseline” Building vs. “Proposed” Building with 2-Series Counter-Flow Chillers

ASHRAE 90.1-2004 “Baseline” Building• Commercial Office Building with Data Center• Internal Loads

– Lights, People, Computers

• Envelope Based on ASHRAE/IESNA Standard 90.1-2004• Operating Schedules per ASHRAE 90.1-1999 User’s Guide



Flat RateUtility Rate: Natural Gas

Complex Rate with Demand Ratchet ChargesUtility Rate: Electric8760 Hourly AnalysisSimulation Program12 ftFloor-to-floor Height

540,000 ft2 Space SummaryConditioned Area

Office (Building Area Method)Space (Building) Usage5AClimate Zone

USA_Syracuse_TMY2.HW1Simulation Weather Data

96.4/75.4 F (1% cooling design DB / MCWB)78.6 F design WB 18 F (99.6% heating design)

Design Weather DataSyracuse, NYLocationApril 28 Green Done EasyProject Name

Project Data: Weather, Climate, Space Usage (Baseline & Proposed)Project Data: Weather, Climate, Space Usage (Baseline & Proposed)


Project Data: (Baseline & Proposed)Project Data: (Baseline & Proposed)

25% of Total Building Energy Cost25% of Total Building Energy CostReceptacle and Plug Loads

ASHRAE 90.1-2004 Section 7.4.2Same as ProposedService Hot Water

Series Counter-Flow screw chillers with chilled beams

VAV, CW/HW per ASHAE 90.1-2004 G3.1.1 through G3.1.3

HVAC Systems

“ “ “ ““ “ “Thermal Blocks

ASHRAE 90.1-2004 Table G3.1“ “ “Lighting

ASHRAE 62.1-2004“ “ “Ventilation

Per“ “ “ ““ “ “Building Envelop and Schedules

“ “ “ ““ “ “Space Usage Classification

ASHRAE 90.1-2004 Table G3.1Same as ProposedDesign Model

ProposedBaselineDescription


Baseline System TypesTable G3.1.1ABaseline System TypesTable G3.1.1A

*Reprinted by permission form ASHRAE Standard 90.1-2004. This material may not be copied nor distributed in either paper or digital form without ASHRAE’s permission.


Baseline System DescriptionsTable G3.1.1BBaseline System DescriptionsTable G3.1.1B




Baseline Chilled Water Plant DescriptionsBaseline Chilled Water Plant Descriptions



• Axial with two-speed fans

• 85°F condenser water design supply temperature or 10°F approach to design wet-bulb temperature, whichever is lower

• Design temperature rise of 10°F

• 19 w/gpm condenser water pump

Baseline Cooling TowerBaseline Cooling TowerSection G3.1.3.11 Heat Rejection


Baseline Chiller PlantBaseline Chiller Plant

Hydraulic Decoupler

(Bridge)

Primary Loop Variable Speed Secondary Loop

Cooling Tower

Sections G3.1.3.7 - 10Parallel Chiller Plant Chiller Eff = 0.576 kW/Ton, Capacity =1.15 X Load44/56°F chilled water with reset22 w/gpm chilled water pump


Proposed (Series Counter-Flow)Proposed (Series Counter-Flow)Series Counter-Flow Chiller Plant Primary Variable Speed Loop44/60°F with resetChilled water pump sized for 22 W/gpm

Flow Meter




Bypass

Cooling Tower



Second Objective:

To understand the fundamental design criteria for a dedicated outside air system (DOAS) to overcome zone latent loads.

To understand the chilled water temperature control criteria and system design as it relates to protecting against condensation formation on chilled beams.

Second Objective:Second Objective:

To understand the fundamental design criteria for a dedicated outside air system (DOAS) to overcome zone latent loads.

To understand the chilled water temperature control criteria and system design as it relates to protecting against condensation formation on chilled beams.


Proposed System - Green Done EasyProposed System - Green Done EasySeries Counter-Flow Chiller Plant with VFD Equipped Screw ChillersPrimary Variable Speed Chilled Water Loop, with High Delta T 44/64°F Chilled WaterDOAS with Energy RecoveryActive Chilled Beams on Secondary CW LoopOptimized Cooling Tower with 3.0 gpm/ton Flow


Dedicated Outdoor Air System

100% Outside Air

75% Effective ERW

Chilled Water Coil, 44/54°F

SAT-DP to Overcome Zone Latent Loads

Fan Hp per ASHRAE 90.1-2004


Dedicated Outdoor Air System

Must overcome zone latent load with primary supply air

Very important to maintain zone RH levels and minimize potential for condensation formation on chilled beams



Dedicated Outdoor Air SystemDetermine DOAS Supply Air Dew Point Temperature (SAT-DP)

Select the cooling coil LAT to be cold/dry enough to limit zone RH to 50%

Use HAP “Hourly Zone Loads” Report


Psychrometric Analysis

20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105 110

78

910

11

1213

1415

1617

18

1920

2122

2324

2526

2728

2930

3132

3334

3536

3738

3940

4142

4344

4546

4748

49

0

10

20

30

40

50

60

70

80

90

100

110

120

130

140

150

160

170

180

1.000.950.900.85

0.80

0.75

0.70

0.65

0.60

0.55

0.50

0.45

0.40

0.35

SensibleHeatFactor

.000

.001

.002

.003

.004

.005

.006

.007

.008

.009

.010

.011

.012

.013

.014

.015

.016

.017

.018

.019

.020

.021

.022

.023

.024

.025

10% RELATIVE HUMIDITY

20%

30%

40%

50%

60%70

%80

%90

%

25

30

35

40

45

50

55

60

65

70

75

80

12.5

13.0

13.5

14.0 VOLUME- CU.FT. PER LB. DRY AIR

14.5

0.1 Btu

0.2 Btu

0.3 Btu

0.4 Btu

-.02 B

tu

-.04 B

tu

-.06 B

tu

-.08 B

tu

-0.1 B

tu

-0.2 B

tu

-0.3

Btu -

Enth

alpy d

eviat

ion B

tu pe

r pou

nd of

dry a

ir

Dry-BulbTemperature F

Wet-BulbDewpoint orSaturationTemperature F

Pounds of moistureper pound of dry air

Grains of moistureper pound of dry air

Enthalpy at saturation, Btu per pound of dry air

Outdoor Air

After ERW

Cooling Coil

Reheat Coil

Zone Set Point

Zone Sensible

BAROMETRIC PRESSURE: 29.921 in. HG

PSYCHROMETRICCHARTNormal TemperatureI-P UnitsSEA LEVEL

Cooling Coil SAT-DP 47.2°F Dew Point


High sensible load capacity (offices, schools, computer rooms)Decouples ventilation load from room sensible + latent loads resulting in

better temperature control and fan energy savingsTypical supply air temperature is 64-65F exiting the chilled beam maximizing

occupant comfort. Conventional systems deliver cold air at 55F with the potential of creating drafts if poor mixing occurs

Constant volume ventilation air eliminates potential air dumping as compared to varying airflows in VAV system.

Reduced fan power requirements (100-250 CFM/ton)Increased ventilation effectiveness (1.0) due to the good mixing (high

induction ratio) of room air and supply airReduced plenum space required (units are ~12” tall), good for retrofit

applicationsEasily integrates with T-bar (false) ceilings

Some units incorporate fluorescent lighting fixtures and fire sprinkler heads

Chilled Beam ApplicationsChilled Beam Applications


Active Chilled BeamInduction air current mixes room air with ventilation air.

Sensible cooling provided by chilled water coil.



Active Chilled BeamInduction air current mixes room air with ventilation air.

Sensible cooling provided by chilled water coil.


Chilled Beam Cooling Saves EnergyChilled Beam Cooling Saves Energy

Tempered Ventilation Air.

Only Enough for ASHRAE 62.1 Requirements

Higher Temperature Chilled Water

for Room Sensible Cooling.

Maximizes Chiller

Efficiency

Induced Air Flow Minimized Fan

Energy, Ensures “No-Draft”Comfort

Excellent Heating

Capability with 2 or 4-Pipe

System


Chilled Beam Air InductionChilled Beam Air Induction

Induced Air

Temperature profil Velocity profil

Cooling Coil

Supply Air Room Air


Proposed System - Green Done Easy“The LEED® Platinum Solution”Proposed System - Green Done Easy“The LEED® Platinum Solution”Series Counter-Flow Chiller Plant with 23XVR ChillersPrimary Variable Speed Chilled Water Loop, with High Delta T 44/64°F Chilled WaterDOAS with Energy RecoveryActive Chilled Beams on Secondary CW Loop Controlled by Zone Dew Point SensorsOptimized Cooling Tower with 3.0 gpm/ton Flow and Low Approach Temperature



Fourth Objective:

To understand how software applications evaluate the potential LEED Energy and Atmosphere Credit 1 points for the Green Done Easy system.

Fourth Objective:Fourth Objective:

To understand how software applications evaluate the potential LEED Energy and Atmosphere Credit 1 points for the Green Done Easy system.


PRM Method….What Is The Procedure?PRM Method….What Is The Procedure?

Grand Total

Non-HVAC Sub-Total

Misc. Fuel Use

Misc. Electric

Electric Equipment

Lights

HVAC Sub-Total

Cooling Tower Fans

Pumps

Heating

Cooling

Air System Fans

Proposed Building ($)Component

Table 1 – Annual Costs

Proposed Building Baseline Building(s)

0° Rotation (same as Proposed)

90° Rotation

180° Rotation

270° Rotation

Average Baseline


Hourly Analysis Program (HAP)Hourly Analysis Program (HAP)

Streamlined LEED EA Credit 1 Analysis• LEED NC 2.2 EA Credit 1 Summary Report. Imitates on-line submittal template. Eliminates hours of work!

• Automatic Duplicate Baseline Building - Places Proposed and Baseline buildings in a single project so the Credit 1 Summary Report can be generated. Saves time!

• Building Rotations - Automatically makes "Baseline 0, 90, 180, and 270 Degree" and all of its systems, plants, spaces, chillers, cooling towers and boilers. Less errors inputting data!

• Autosize DX and Plant Equipment. 115% and 125% equipment gross capacity. Faster analysis!

• DX Equipment Performance as EER or COP. Assesses EER or COP to determine compressor kW. Saves time!

• Baseline Fan kW Calculator - Sets the total fan kW for the system. No hand calculations!

• Fan Performance Defined as W/CFM and ASHRAE 90.1 Appendix G VAV Fan Part-Load Curve. Faster analysis!

• Water Flow Rate Inputs as gpm/Ton or Delta-T. and Water Pump Performance as W/gpm or kW. No hand calculations!

• Plus more Wizards to make data entry faster!© 2009 Carrier Corp.

Hourly Analysis Program (HAP)Hourly Analysis Program (HAP)



Determine LEED® Credit Points for Proposed BuildingDetermine LEED® Credit Points for Proposed Building

• EAc1 Points

• % Savings = $ 989,348 – $669,807 = 32.3 % $ 989,348

New Construction or Major Renovation

EA Credit Points

10.5% 114.0% 217.5% 321.0% 424.5% 528.0% 631.5% 735.0% 838.5% 942.0% 10

7 points!

Green Done Easy

Kwhr / year CO2 Reduction Energy SavingsNOx Reduction

$ 319,5412,287 lb1,936,972 lb1,760,883

44 F 54F 60 F

FL kW/ton IPLV kW/ton

0.576 0.5490.488 0.294


Hydraulic Decoupler

(Bridge)

Primary Loop Variable Speed Secondary Loop

Cooling Tower

Flow Meter




Bypass

Incorporates into your existing designIncorporates into your existing design


Greenhouse Gas EmissionsGreenhouse Gas Emissions

[1] Average Annual Emissions and Fuel Consumption for Passenger Cars and Light Trucks, Emission Facts, United States Environmental Protection Agency, Air and Radiation, Office of Transportation and Air Quality, EPA420-F-00-013, April 2000, Passenger Cars = 11,450 lbs CO2/year; 38.2 lbs NOx/year

It’s like taking…Over 170 cars off the road!

Eliminates over 970 tons of CO2

per year!


Copyright © Carrier Corp. 2009Copyright © Carrier Corp. 2009

Thank you!

Green Done Easyfor

LEED® Certification

Documents

Feduik Series-Counterflow Green Done Easy · • Typical entering condenser water from tower • Typical entering wet bulb to tower • Typical difference between water leaving the